Machine and method for forming arched roof vertical wall self supporting metal buildings

ABSTRACT

A mobile metal building forming machine forms panels of predetermined length from a coil of flat metal and then the formed panels are continuously crimped on their side edges for strength and are selectively curved by crimping the bottom of the panel. The crimping and curvature are automatically controlled so that building panels with vertical walls and an arched roof may be formed. A moveable crimping roll is automatically portioned to control the curvature and the roll is chain driven so that it may be moved without affecting its rotational drive.

BACKGROUND OF INVENTION

1. Field of the Invention

This invention relates to improvements in machines and methods forconstructing metal building and building configurations, and moreparticularly relates to arched roof, vertical wall, self supportingmetal buildings formed of adjacent seamed together panels and a methodand machine for forming such panels.

2. Background and Prior Art

It is known in the prior art to make metal buildings from adjacentformed metal building panels which are arched or curved, assembled sideby side and seamed together. See for example, Knudson U.S. Pat. No.3,902,288 (1975) for showing of such building in which the roof panelsare completely curved or arched and extend to the foundation. In suchbuildings the roof panels continue as the side walls of the building andthe basic building construction is in the shape of a continuous arch orsemi-circle when viewed from the end. A machine for making the metalpanels for such building in which the formed panels are corrugated notonly on the side edges of the box, but also on the bottom to create thecurvature is shown in Knudson U.S. Pat. No. 3,842,647 (1974). A methodof building the building by adjacent panels which are seamed together isdisclosed in Knudson U.S. Pat. No. 3,967,430 (1976). A seamer forforming the seams between the adjacent panels of the prior Knudsonpatents is shown in Knudson U.S. Pat. No. 3,875,642 (1975). The priorart represented by the Knudson patents is owned and has beencommercialized by MIC Industries, Inc. of Reston, Va. in its mobileK-Span® machines.

An arched building construction i.e., construction of which walls androof are completely arched has advantages, but also, a number oflimitations. One limitation is the absence of vertical walls whichlimits the use of vertical space. Often users of metal buildings wantvertical walls both for aesthetic purposes and to allow more use ofspace near the edges of the building. Additionally, known prior artmachines had a limitation on the thickness of steel used in forming themetal panels, because of machine limitations. The basic size andstrength of such metal buildings is also limited by local wind and liveload limitations as established by building codes throughout the nationand the world. As these building code standards become moreconservative, a builder is effectively limited to only certain sizebuildings. The complete arched building must be limited in size in orderto prevent overloading such as could occur from extensive wind loadsproduced by hurricanes. However, when the total roof height is reducedto approximately one-fifth of the total building width, hurricane forcewinds to not affect the building as much, because of reduced frontalarea. Thus, there is a need in the art for a metal building formed ofcontinuous panels which is not completely arched but has straightvertical walls while utilizing the economy of the seamed panelconstruction of the prior art. Such vertical wall buildings wouldsatisfy a need in the art for space, economy, usefulness and strength.

In addition to the prior art discussed above, Knudson U.S. Pat. No.4,039,063 (1977) discloses a run out apparatus and method for handlingformed panels to produce arched metal buildings. As shown in the patentrun out tables can be positioned to collect the curved panels.Additional patents exist in the art for forming and assembing relativelywide panels for arched metal buildings, see Knudson U.S. Pat. No.4,364,253 (1982) U.S. Pat. No. 4,505,143 (1985), U.S. Pat. No. 4,505,084(1985) and the seamer therefor in Knudson U.S. Pat. No. 4,470,146(1984). These patents are owned by and commercialized in M.I.C.'s SuperSpan® mobile metal forming machines. In the prior art the radius of thearch could only be adjusted by manual means. Furthermore, the radius ofthe arch could only be adjusted to a desired curvature when there was nomaterial in the machine. The procedure for radius adjustment includedsetting dials to a reference number to form a predetermined length ofmetal then forming the metal and comparing it to a radius gauge thatmust be made from a plywood template or a similar radius measuringdevice. If after inserting a piece of metal in the machine and curvingit, the radius is incorrect, the operator must dial a new set of numbersand rely on experience and rules of thumb to help him achieve the properradius. In order to achieve the proper curvature for arched panels, upto 500 pounds or more of metal may be wasted by bending them to thewrong curvature, depending on how skilled the machine operator is. Thus,there is need in the art to provide for automatically and controllablyadjusting the radius of curvature and to be able to accomplish that withmaterial in the machine, so that no material is wasted reaching thedesired curvature.

Another drawback in the prior art is that the dials set to control theradius of the panel independently operate on the top side of the panelor the bottom side. Failure to adjust the two dials properly will causethe curved panel to distort and produces panels which are unacceptablefor building use and must be scrapped. Distortion is sometimes termed“corkscrewing.” Thus, there is need in the art to allow automatic andcontinuous adjustment of the curvature of the panels by a semi-skilledoperator.

Another deficiency in the prior art arched panel forming machines isthat they do not produce straight sections and curved sections togetheron the same panel. Furthermore, straight panels formed separately andused as vertical wall building panels are weak because they are notcrimped. In other words with the existing technology, crimping just thesidewalls of the panels cannot be accomplished. But there is a need inthe art to provide for a crimping of the side walls of straight panelsused as vertical building walls.

Furthermore, the prior known machines for producing arched metalbuilding panels have main crimping rollers which when being adjustedseparate from each other causing diminished contact area of the gearsresulting in significant premature gear wear. Also, when the crimpingrolls of the prior art become separated, it is very difficult tore-engage the gears without physically guiding them into position whichrequires the machine operator to adjust the machine with moving machineparts, which is unsafe. Furthermore, when the main rolls are separatedand the gear teeth are so far out of mesh, the gear backlash is severe,causing the main crimpers to turn out of time with each other andresults in unacceptable finished panels. There is a need in the art foran improved drive train of the main crimping rolls which eliminates theabove mentioned problems and allows for an extremely smooth trouble-freeautomatic crimping operation.

In the prior art, the operation of the machine was manual and thehydraulic system was adequate, however, it is desirable to allowsimultaneous use of components and automatic and continuous adjustmentof the crimping operation while allowing the hydraulic control of thepanel former, shear blade and other controls. Thus there is a need inthe art for automatic controls from a control panel so that asemi-skilled operator can automatically control the forming machine toproduce panels of any desired curvature including portions of which thatare straight and not curved.

There is also need in the art for an improved building method forjoining multiple buildings together and providing column support for theside walls without significant conditional components.

SUMMARY OF THE INVENTION

This invention provides a machine for forming panels to make buildingsin which a portion of the panels are curved and the curvature isautomatically controlled. The machine also makes panels which arestrengthened by crimping and which panels may have a straight as well asa curved portion so that the panels can be used to construct a buildingwith an arched roof and vertical walls. Automatic control of the machineis through hydraulics and a microprocessor controlled by measuring andmonitoring of the panels formed. The curvature of an arched portion ofthe panel is controlled by the extent of crimping of the bottom of thepanel and extent of crimping is determined by the automaticallycontrolled spacing of main crimping rolls. Moreover, the controls areoperable during forming of the panels and with the panels in thecrimping rolls. Automatic positioning of the crimping rolls isaccomplished without premature wear on the roll drive gears or unduebacklash, i.e., it is accomplished with an extremely smooth,trouble-free drive train. The hydraulics of the system together with theelectrical control features allow the machine to be operated by asemi-skilled worker without a great deal of experience.

The invention also includes a building method and a buildingconstruction in which multiple buildings are joined together withoutadditional columnar support, i.e., using the side walls as columns. Thisis accomplished by assembling two vertical panels back to back toprovide a stiff column with an extruded fastening member reinforcingbars and concrete within the space between the vertical panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of the machine of this invention illustratingthe general arrangement of the component parts and with some portionsbroken away and other positions shown only schematically for clarity.

FIG. 2 is a partial top plan view of the machine of this invention withportions broken away for illustrating the main crimping rolls and thecontrols thereof.

FIG. 3 is a view somewhat similar to FIG. 2 but with different elementsremoved for showing the drive train for the main crimping rolls.

FIG. 4 is a front elevation view showing the positioning of a measuringdevice for measuring the amount of panel which has passed apredetermined point.

FIG. 5 is an end elevation view of the assembly shown in FIG. 4.

FIG. 6 is a top plan view with a portion broken away of an assembly ofthe device for moving the crimping rolls and accurately measuring itsposition.

FIG. 7 is a sectional view taken along lines 7—7 of FIG. 6.

FIG. 8 is a side elevation view illustrating the drive for moving themain crimping rolls with portions broken away for the aid of clarity.

FIG. 9 is a top plan view of the radius measuring device with coversremoved.

FIG. 10 is an end elevation view illustrating the control panel forcontrol of the machine from one spot by semi-skilled operator.

FIG. 11 is a schematic diagram illustrating the connections from thehydraulic and electrical systems for the automatic control of the entiremachine.

FIG. 12 is a schematic end elevation view of one shape of a buildingthat can be made using this invention.

FIG. 13 is a perspective view illustrating a detail of the building ofFIG. 12 showing the assembly where the building is assembled, andillustrating the self support.

FIG. 14 is a schematic end elevation view of another shape of buildingwhich can be made using this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows the general arrangement of the machine of this inventionwhich is preferably mounted on a trailer 30 so as to be mobile andmoveable to an on site location for forming the metal panels which willbe used in erecting the buildings. The components of the machine areassembled on a deck 32 of the trailer and include a roll holder 34, forholding a roll 36 of sheet metal of appropriate gauge from which thebuilding panels are formed. Along one side of the machine adjacent tothe supply roll of metal there is a roll forming machine 38 whichincludes a plurality of metal forming rolls for forming the sheet metalinto a desired configuration. Since this roll forming machine is knownin the art mentioned above it need not be shown or described. The crosssectional shape of the metal leaving the forming rolls may be that knownin the art and as shown in the prior patents identified above, whereinthere are different shaped panels which are assembled side by side withthe edges crimped together by a seamer, also as known in the art. At theend of the roll forming station there is a hydraulically operated shear40 for shearing the desired and measured length of the formed panel.

An internal combustion engine 42 (preferably a diesel engine) is mountedon the trailer for supplying hydraulic power via a hydraulic pump 44. Amain hydraulic valve 46 is mounted on the trailer for controllablyfeeding hydraulic fluid for various hydraulic actuators. An operatorcontrol panel 48 includes various controls, readout panel and amicroprocessor.

Panel forming rolls of the panel roll forming section 38 are powered bya hydraulic motor 50. Other hydraulic motors 52 are provided forcrimping the side of the formed panel P and forming the crimp C_(s) asis known in the prior art. Another hydraulic motor 54 is provided fordriving the panel bottom crimping rolls to provide a bottom crimp whichdetermines the curvature of the panel, the bottom crimp being shown asC_(b).

A panel length measuring device 56 is provided for measuring the lengthof the formed panels electronically from the roll forming machine.Another substantially identical panel length measuring device 58 ispositioned on the other side of the machine for measuring the length ofthe formed panel being fed to a crimping and curving section 68.

The hydraulic shear 40 is operated by hydraulic cylinders 62. Run outsupport tables 64 are positioned adjacent to the shear and in line withthe roll forming section 38 to support the formed panel. The trailerwill have appropriate racks 66 for storing the support tables 64 and 78and other essentials equipment while the trailer is being transported.

On the side of the trailer opposite the roll forming section 38 is thecrimping and panel curving section 68. The bottom crimping to producethe crimp C_(b) is accomplished by a pair of crimping rolls 70 and 72. Acurvature measuring device 74 contacts the panel following the bottomcrimping rolls to determine the radius or degree of curvature that thebottom crimping is causing the panel to assume. Because the bottomcrimping controls the degree of curvature and the degree of bottomcrimping is controlled by the distance between the axis of the crimpingrolls 70 and 72, movement of one crimping roll relative to the otherdetermines the degree of curvature. Hydraulic motor 75 is provided tomove crimping roll 70 relative to roll 72 to control the degree ofcurvature. The side crimping for the side of the panel is provided byside crimping rolls 76 driven by motors 52. Run out tables 78 areprovided for receiving the formed panel.

The crimping rolls 70 and 72 can be completely disengaged from thebottom of the panel P in which case the panel will not have curvature(i.e., crimp C_(b) will be absent) and the panel will be straight, butwill be straightened by the side crimps C_(s). By automaticallycontrolling the engagement and position of the crimping rolls the formedpanel may have a straight section or sections and a curved section orsections with the degree of curvature or the radius of the curvedsection being accurately and automatically controlled. When it isdesirable to have a building with vertical side walls the panels formedby the machine of this invention can be set to provide formed panelswith straight sections either with an arched roof or straight (sloping)roof with a radius or curved section between the walls and at the apexof the roof. All methods for controlling this machine and the formedshapes described are all programmably controlled. The panels formed bythe machine of this invention may be seamed together by seamers astaught in the prior art.

As shown in FIG. 2 an electronic encoder 80 is associated with panellength measuring device 58 and is used for measuring the length of panelwhich is run through the side crimping rolls. Another electronic encoder82 is used for determining the position of the crimping rolls relativeto each other, i.e., the depth of crimp if any. The curvature measuringassembly 74, also detailed in FIG. 9 includes measuring assembly 84which, when contacting the curved panel, will measure the curvature,This is achieved by when the fixed arms 86 contact the panel within afixed distance, the vertical or height dimension of the arc length willbe determined by assembly 84. The mechanical linkage 88 will positionthe electronic encoder 90. This encoder will send the electronicinformation back to the microprocessor for further controlling themachine.

The rotational drive of the crimping rolls is shown in FIG. 3. Thecrimping roll hydraulic motor 54 drives the shaft to which sprocket 92is fixed and sprocket 92 drives chain 94 trained over sprocket 96. Thereare two sprockets 96 spaced side by side on the shaft and chain 98 istrained over one of them and sprocket 100. Another sprocket 100 on thesame shaft carries drive chain 102 trained around sprocket 104 fixed todrive shaft 106 of crimping roll 70. A pinion 108 is fixed to the shaftof sprocket 96 and a drive gear 110 is fixed to the drive shaft ofcrimping roll 72 for the drive of that roll. A tension assembly 112 isprovided for tensioning chain 102 which is variably positioned due tothe position adjustment of roll 70 under the control of motor 75.

In the prior machines of this type crimping rolls were driven by threespur gears directly coupled. When the main crimping roller moved awayfrom the gears the contact ratio was small and the gears sufferedpremature wear and failure. With the present construction the maincrimping rolls 70 and 72 are mechanically coupled but complete freedomof movement is allowed without affecting the timing and without gearbacklash.

FIGS. 4 and 5 show the measuring device assembly such as 56 and 58 forelectronically measuring the length of formed panels. The encoder 80 isconnected through a water tight plug and harness 114 to themicroprocessor. The measuring roller of cylindrical shape 124 rollsfreely via bearings 122. This roller is machined from phenolic materialwhich is very wear resistant and provides adequate friction needed foraccurately measuring the panels. The support and mounting for theassembly includes a mounting plate 126 secured to the frame of themachine by bolts 128. The measuring device is movably mounted and biasedby extension spring 130 attached to spring tab 132 on mounting plate 126and tab 134 on a moveable frame 136 of the measuring roll. Moveableblock 138 slides on a rail 137 so that the frame 136 carrying the roll124 can move up and down always being pressed against the underside ofthe panel P by the bias from spring 130.

For moving the crimping roll 70 it is mounted to a plate and moveablethrust block 142, see FIGS. 6 and 7. A bronze nut 144 and retainingflange 146 is assembled to an Acme threaded rod 148, which is rotated bymotor 75. This threaded rod rides within the nut 144 and allows thethrust block to move radially of the rollers giving the crimper itsdesired movement ranges. The use of the nut allows very slow rotationfor example 1 to 2 rpms and very high speed returns around 40 to 50 rpm.As the thrust block 142 is moved radially it in turn moves mechanicallinks 150, 120 and 153 which are connected to the thrust block by clevis154 and also connected to the encoder 82 to determine the position ofthe crimping rolls.

FIG. 8 shows the drive for both ends of the shaft of lower crimping roll70 which are moved together to the same position. Sprocket 160 isattached to shaft 148 and is driven by chain 164 trained around sprocket162 which in turn is connected to a gear reduction unit 166 driven byhydraulic motor 75. Another sprocket chain 170 is trained around anothersprocket 160 and a further sprocket 172 on shaft 174. Shaft 174 issimilar to shaft 148 and controls the other end of roll 70. Both ofthese shafts are the ends of the threaded rods 148. With the properposition of the crimping rolls the accuracy of the finished panels canbe accomplished to eliminate the waste typically obtained as a result ofusing the prior art machines.

FIG. 9 illustrates the control panel 48 which also houses themicroprocessor. Portion 168 of control panel 48 is for the enginecontrol and includes fuse 176 and ignition switch 178, an alternatorindicator 180 and a starter switch 182. The engine motor which ispreferably a diesel engine may be controlled at either high or lowspeeds through control 184 and has a pilot light 186 to indicate theignition is on. The number of hours the engine has operated is indicatedon gauge 188 and the engine oil pressure is indicated on gauge 190.Reset button 192 is utilized to reset the control. In the upper rightportion of control panel 48 is the microprocessor control panel 193which includes an increase radius button 194 and a decrease radiusbutton 196. Building type may be controlled by pushing building typebutton 198 and entering digits corresponding to the building type, i.e.,the shape of the panel to be formed. Conversion of English to metricunits is accomplished through the manager mode key switch 198. Thethickness may be entered into the microprocessor for controls bypressing the F key 195 and the THK button 198 and the particularthickness on the keypad 208. A display panel 210 is used to display theactual and desired radius and the length. It is also used to display allcontrol and error functions of the microprocessor. For setting aparticular length or radius control buttons 204 and 206 are pushed andthen the length or radius is set using entry into the microprocessor viathe keypad 208.

Control of the panel feed through the panel forming assembly 38 isaccomplished by control buttons 212, 214 and 216. Button 214 is thepanel feed slow button for initial feeding of the panel into theassembly to be sure everything is correct. The panel former start 214 isused to feed the panel at high speed through the panel former. It shutsoff automatically when the desired length is achieved. Panel reversebutton 216 is for reversing the forming rolls to feed the panel back outof the former.

The switches on the panel 48 for the curver section 68 have the samefunctions, namely, feeding the panels slow 218 through the curver,reversing the curver 222 or running it at high speed (normal) 220. Thehydraulic shear 40 is operated up and down by a control 224 and theentire machine may be shut down by an emergency stop control 226. Acomputer RS232 serial port 199 is used to communicate the microprocessorwith a personal computer. Switches 213 and 215 are used to reset thepanel former and curver respectively. Buttons 181 and 183 are used totemporarily stop the panel former and curver respectively. Button 199 isused to change any function when the machine is running. Aclear/calibrate button 193 is used to clear entries and calibrate themachine. The manager mode 198 will allow the operator to check and/orchange one hundred different operating parameters of the machine.

FIG. 11 is a schematic illustration of the components for controllingthe machine. The engine 42 drives the main hydraulic pump 44 whichreceives hydraulic fluid through line 228 from reservoir 227. Variablevolume piston pump 44 pumps hydraulic fluid through line 232 to the mainhydraulic valve 46. The pressure is measured and monitored via gauge224. The main hydraulic valve has four sections 234, 236, 238 and 240.Hydraulic valve section 234 controls the operation of the panel formingdrive motor 50 and is controlled by control buttons 212, 214, and 216 oncontrol panel 48 and inputs from the microprocessor. Section 236 of themain hydraulic control valve 46 is for controlling the operation ofhydraulic shear 40 by operating the hydraulic cylinders 62 for operatingthe shear and moving the shear either up or down via hydraulic lines 237and 239 as shown. Control valve section 238 is for controlling the driveof the crimper roll drive motors 52 and 54. The hydraulic fluid ispassed through lines 250 to motors 52 and 54 and back through lines 252.The motors rotate the crimping rolls as previously described. Hydraulicvalve section 240 controls the crimping roll positioning motor 75through hydraulic lines 260 to move the crimping roll 70 toward or awayfrom roll 72 in order to control the degree of curvature from a straightpanel to a panel with a desired radius.

An audible alarm 246 is connected via electrical line 248 to themicroprocessor and main control panel 48.

The microprocessor controls all four valve sections 234, 236, 238, 240through signals sent via electrical harness 242.

The panel length measuring device 58 sends signals to the microprocessorthrough harness 244 and the microprocessor then controls the speed andduration of drive via motor 50 according to that preset for panel lengthby the control panel.

Similarly, the length measuring device 58 feeds signals throughelectrical lines 254 to the microprocessor incorporated behind thecontrol panel 48 and signals are fed via line 242 to control valveportion 238 to control the amount and the drive of the motors 52, 52 and54 and hence the length passing through the crimper rolls. The curvaturedetected by radius measuring device 74 is fed through harness 258 to themicroprocessor and the microprocessor sends back signals to controlvalve 240 to control crimping roll positioning motor 75 to position thecrimping roll and control the radius. The position of the crimping roll70 is detected by encoder 82 which feeds its signal through line 256 tothe microprocessor which in turn sends signals to valve section 240 toaccurately determine the position and hence further control motor 75 toposition the crimping roll.

Operation of the machine will now be described. The machine starts witha coil of flat steel on roll 36 positioned on trailer 30. Under thecontrol of panel switches 212, 214 and 216 the steel is fed through thepanel forming section 38 driven by hydraulic motor 50 to an extentdetermined by the length entered in via keypad 208 and length button 206in the control panel. As the panels are formed the sensor 56electronically measures the panels as they are coming off the rollforming line sending input signals through a line 244 back to a controlpanel and microprocessor 48. When the desired length is achieved themotor 50 shuts down automatically and the controls signal the operatorto shear the panel via shear 40. The operator then operates shearcontrol button 214 to shear the panel and the sheared panel rests onrun-out table 64 supplied with the machine. The table 64 will hold thepanels until they are ready to be curved through the curving section 68.The machine is capable of producing multiple different panels dependingupon the shape of the rolls in section 38. A panel 24 inches wide or 22inches wide may be formed with a coil 36 inches wide, a panel 12 incheswide or 16 inches wide may be formed from, a 24 inch panel and a 20 inchpanel may be formed from a 36 inch wide coil.

The formed panel is then fed back through the curving assembly 68 andthe sides are crimped via side crimping roll 76 under the control ofmotors 52. The operator then enters the desired radius by pushing theradius button 204 and the keypad may be used to set the radius. Encoder82 will determine the position of the main crimping roll 70 relative toroll 72. The operator then inserts the panel into the curving sectionand starts the curving process using buttons 218 to start and thenswitching to button 220. The side crimping motor 52 will drive the panelthrough the curving section under hydraulic power and the main crimpingrolls 70, 72 are also hydraulically operated for rotational drive bymotor 54. The encoder 74 will rest on the crimped panel and measure theappropriate radius. If the radius measured does not match as the desiredradius entered into the microprocessor the encoder 74 will send thesignal back to the main panel through line 258 which will operate valve240 to cause motor 275 to reposition crimping roll 70. The encoder 82receives a signal from the microprocessor through line 256 informing thecontroller that a new radius will be used. This is then stored into themicroprocessor for future reference. The crimping roll 70 is adjusted tothe desired radius and when this is achieved the microprocessor willalert the operator and the panels continue to be formed, and they reston layout tables 78.

In order to construct special buildings with a portion of the panelstraight and other portions having one or more desired radius ofcurvature, the operator inputs the information into the control panelmicroprocessor 48 to send signals to the encoders 74, 58 and 82 tocontrol the curving section. For example, if the operator wants astraight wall, a curved roof and straight wall, the first input from thecontrol panel would be the straight wall length; this could be inputtedthrough the numerical keypads 208. The desired curvature of arch couldalso be inputted followed by input for the final straight section. Also,certain building types which are recurring are given codes which can beinputted to the microprocessor after pressing the “Type” button 198. Themachine can measure through the measuring device 58 the appropriatelength of a straight portion of the panel P. At this point only the sideflanges are crimped leaving the center bottom untouched so that it isnot curved. When the desired length is achieved the microprocessor tellsthe drive motors to stop. At this point the crimping roll 70 will movein a position via hydraulic motor 75 and its gear reducer. Themicroprocessor then commands the drive to continue forming the panels inan arch shaped section while carrying the straight wall across the runout table. Once the proper arch length is achieved, the machine stopsagain so that the main crimping roll can pull away from the panel andallow a third and last section to be formed as a straight section. Themicroprocessor will control all these functions including proper delaytimes, proper radius and proper length of the panels. The control panel48 also includes manual overrides 194 and 195 to allow the operator tomake emergency adjustments to radius control. These override switchescontrol valve 240 to feed motor 75.

Building type button 196 can give the operator flexibility when choosinga desired building type inputting a single command via keypad 208. Thethickness entry via keys 195 and 198 is primarily for the memory of themicroprocessor.

FIG. 12 shows one type of building 226 that can be built using thisinvention. A panel span 270 has an arched roof 272 sandwiched betweentwo vertical wall portions 274. In this case the entire building 266 isformed by assembling panel sections side by side as shown in FIG. 12 inwhich the vertical side walls 274 are back to back and attached togetherforming a common vertical wall 276. This building can also be used as asingle or multiple unit. The assembly may conveniently be erected onfootings or foundations 268 as is known in the art.

A detail of the common vertical wall 276 is shown in FIG. 13. The panelswhen assembled together form a section with cavities of hexagonal orhoneycomb shape 278. Reinforcing bar assemblies 280 may be placed inthese cavities and the cavities may be filled with concrete (not shown)for rigidity and support. Extruded aluminum panels 282 may be assembledbetween the panels and attached by fasteners 284 to secure the panelstogether in a back to back manner. Electrical conduits may be passedthrough cavities 286 in the extruded members or may be passed throughcertain of the cavities 278 which then would not be filled withconcrete.

FIG. 14 depicts another form of completed building structure. Thesebuildings are formed using straight vertical walls 280, separated fromthe sloping straight roof portion 282 by a curved section 284. A smallcurved section 286 at the apex of the building will complete the shape.Two or more buildings can be constructed by using the vertical columnsupport 276 as previously described. This concrete vertical column canalso be used on straight vertical walls in single buildings as well.

As can be seen this invention provides a unique machine forautomatically and controllably forming sheet metal into panels for metalbuildings together with a unique method for forming desired panels and anew building type. It is the intention therefore to be limited only bythe scope of the appended claims.

What is claimed is:
 1. A machine for automatically and controllably forming sheet metal into panels for metal buildings having combined walls and roof panels, at least a portion of which are arched or curved; the machine comprising; a) roll forming means for roll forming sheet metal material into a desired panel profile having a central bottom portion between upturned lateral edge portions; b) shear means adjacent the roll forming means for shearing the roll formed panel; c) crimping means for continuously crimping by bending small folds in the bottom portion of formed sheared panel lengths fed through the crimping means to provide a curvature of the formed panels, the depth of the folds establishing the curvature; d) panel curvature measuring means for measuring the curvature of bottom crimped formed panels; and; e) automatic digital control means for controlling the crimping means to vary the control the extent of curvature of the formed panels by varying the depth of the folds, the automatic digital control means being at least partially responsive to the measuring means and a control input setting of desired curvature.
 2. A machine as defined in claim 1 further comprising; means for automatically and controllably adjusting the crimping means only so that the sheared panel bottom portion is not crimped and a corresponding portion of the formed panel is straight.
 3. A machine as defined in claim 2 further comprising; additional crimping means for crimping the edge portions of the formed panels, and length measuring means connected to control means for continuously and automatically measuring the length of formed panels passing through the crimping means.
 4. A machine as defined in claim 1 wherein the crimping means includes a pair of crimping rolls sandwiching the bottom of the formed panel, a moveable block mounting at least one crimping roll so that the crimping rolls may be positioned toward or away from each other, means controlling movement of the block responsive to the control means.
 5. A machine as defined in claim 4 wherein the bottom crimping rolls are driven by chains.
 6. A machine as defined in claim 1 wherein the control means includes a control panel, a microprocessor and hydraulic and electrical circuits.
 7. A machine as defined in claim 6 wherein the control panel allows adjustment of the curvature length of curved portion, and length of straight portion of a formed panel.
 8. A machine as defined in claim 7 wherein the control panel includes automatic shut down means and a computer connection.
 9. A machine as defined in claim 1 wherein the machine is further mounted on a wheel vehicle for mobility.
 10. A machine as defined in claim 9 further comprising hydraulic activated shear means mounted on the vehicle for shearing desired length of the formed metal panel.
 11. A method of making panels for a self-sustaining building formed of such panels seamed together side by side, the method comprising; a) roll forming sheet metal from a roll of sheet metal into a desired cross-sectional configuration having side edges and a bottom; b) shearing the formed configuration at a desired and predetermined length; c) crimping by placing small indentations to the side edges of the predetermined length of formed configuration to add strength; d) curving the sheared lengths of roll formed sheet metal by automatically and controllably crimping by placing small indentations to the bottom of the formed configuration to add strength and to provide a predetermined curvature for a portion of the predetermined length to provide a building panel having a curved roof portion and straight vertical wall portions on opposite sides of the roof portion, the depth of the indentations establishing the curvature; and e) measuring the curvature and the predetermined length of the crimped panel and using such measuring and a predetermined setting of curvature for continuously and automatically controlling the depth of the indentations during crimping without removing the panel from the crimping step.
 12. A machine for automatically and controllably forming sheet metal into panels for metal buildings having combined walls and roof panels, at least a portion of which are arched or curved, the machine comprising; a) a plurality of metal forming rolls arranged to form sheet metal material into a desired panel profile having a central bottom portion between upturned lateral edge portions; b) a movable shear blade adjacent said plurality of metal forming rolls, wherein said moveable shear blade cooperates with an other severing implement to cut said panel; c) crimping rollers for continuously crimping by bending small folds in the bottom portion of said cut panel lengths fed through said crimping rollers to provide a curvature to said formed panels, the depth of the folds establishing the curvature; d) a curvature gauge for measuring the curvature of bottom crimped formed panels, and; e) an automatic digital controller to control the crimping rollers to vary the depth of the folds produced by said crimping rollers to control the extent of curvature of the formed panels, the automatic digital controller being at least partially responsive to said curvature gauge and a control input setting of desired curvature.
 13. A machine as defined in claim 12 further comprising said digital controller automatically and controllably adjusts the crimping rollers so that a portion of the formed panel is straight.
 14. A machine as defined in claim 12 further comprising: additional crimping rollers for crimping the edge portions of the formed panels, and length measurement devices connected to said digital controller for continuously and automatically measuring the length of the formed panels passing through the crimping rollers.
 15. A machine as defined in claim 12 wherein the crimping rollers include a pair of crimping rollers sandwiching the bottom of the formed panel, a moveable block mounting at least one crimping roller so that the crimping rollers may be positioned toward or away from each other, and a motor to control movement of the block in response to said digital controller.
 16. A machine as defined in claim 15 wherein the bottom crimping rollers are driven by chains.
 17. A machine as defined in claim 12 wherein the digital controller includes a control panel, a microprocessor and hydraulic and electrical circuits.
 18. A machine as defined in claim 17 wherein the control panel allows adjustment of the curvature length of curved portion, and length of straight portion of a formed panel.
 19. A machine as defined in claim 18 wherein the control panel includes automatic shut down means and a computer connection.
 20. A machine as defined in claim 12 wherein the machine is further mounted on a wheeled vehicle for mobility.
 21. A machine as defined in claim 20 further comprising hydraulic activated shear blades mounted on the vehicle for cutting a desired length of the formed metal panel.
 22. A method of making panels for a self-sustaining building formed of such panels seemed together side by side, as in claim 11 , wherein said side edge crimping is performed by at least two crimping rollers sandwiching at least one edge portion of said formed panels.
 23. A method for making panels, as in claim 11, wherein said depth of the crimping indentations is controlled by a digital controller.
 24. A method of making panels, as in claim 11, wherein said panels are formed by a machine mounted on a wheeled vehicle for mobility.
 25. A method for making panels, as in claim 23, wherein the depth of said bottom crimping indentations is controlled independently of the depth of said edge crimping indentations.
 26. A method for making panels, as in claim 11, wherein said bottom crimping indentations in a single formed panel have a plurality of depths.
 27. A method for making panels, as in claim 11, wherein said roll forming, crimping and curving steps are performed on a machine mounted to a wheeled vehicle.
 28. A machine as defined in claim 12, wherein said curvature gauge measures the radius of said panel. 